Suspended ceiling and air distribution arrangement

ABSTRACT

A linear air plenum formed of duct board (generally a thickness of fiber glass) carries a linear diffuser. The air plenumdiffuser assembly is used with a ceiling having a series of main and cross-runner T-bars, or similar ceiling support members. With the diffuser carried by the linear plenum, a slot is provided in the ceiling by an air track; alternatively the slot may be defined by an air bar, which includes the diffuser elements in which case the air plenum is provided with an air outlet collar which registers with the air bar. A number of these assemblies are connected end-to-end and arranged parallel to one of the cross or main runners and at right angles to the others. The lengths of the air plenum and the attached diffuser, or air outlet collar, are related to the module upon which the ceiling is designed and the diffuser, or outlet collar, length is less than the overall length of the air plenum. The areas of the air plenums between adjacent diffusers, or air outlet collars, are closed and spaced above the runners to be capable of functioning as air return areas.

United States Patent Lambert SUSPENDED CEILING AND AIR DISTRIBUTIONARRANGEMENT Primary Examiner.lohn J. Camby Assistant Eranziner-Henry C.Yuen ABSTRACT A linear air plenum formed of duct board (generally athickness of fiber glass) carries a linear diffuser. The airplenum-diffuser assembly is used with a ceiling having a series of mainand cross-runner T-bars, or similar ceiling support members. With thediffuser carried by the linear plenum, a slot is provided in the ceilingby an air track; alternatively the slot may be defined by an air bar,which includes the diffuser elements in which case the air plenum isprovided with an air outlet collar which registers with the air bar. Anumber of these assemblies are connected end-to-cnd and arrangedparallel to one of the cross or main runners and at right angles to theothers. The lengths of the air plenum and the attached diffuser, or airoutlet collar, are related to the module upon which the ceiling isdesigned and the diffuser, or outlet collar. length is less than theoverall length of the air plenum. The areas of the air plenums betweenadjacent diffusers, or air outlet collars, are closed and spaced abovethe runners to be capable of functioning as air return areas.

8 Claims, 5 Drawing Figures [75] Inventor: Robert R. Lambert, Glendora,Calif.

[73] Assignee: Wehr Corporation, Milwaukee, Wis.

[22] Filed: Dec. 26, 1973 [21] Appl. No.: 428,424

[52] US. Cl. 98/40 D; 98/114 [51] Int. Cl. F24F 13/02; F24F 7/00 [58]Field of Search..... 98/40 R, 40 D, 40 DL, 114,

[56] References Cited UNITED STATES PATENTS 3.301.165 1/1967 Stanley98/40 D 3.319.558 5/1967 Bodian 98/40 D 3.353.472 11/1967 Lee et a198/40 D 3.383.999 5/1968 Fragnito et a1. 98/40 D 3.411.425 1l/1968Lambert 98/41 R 3.420.439 l/1969 Meckler 98/40 DL 3.444.801 5/1969Lambert 3.516.347 6/1970 May 98/40 D 3.577.904 5/1971 Lambert 98/40 DUS. Patent Nov. 18,1975 Sheet10f3 3,919,92

US. atem Nov. 18, 1975 Sheet20f3 3,919,28

22 f4 Z5 3O US. Patent Nov. 18, 1975 Sheet 3 of 3 SUSPENDED CEILING ANDAIR DISTRIBUTION ARRANGEMENT BACKGROUND or iNvENTioN This inventionrelates to ceiling type air distribution arrangements and, moreparticularly, to an improved construction for delivering air through aceiling slot defined by either an air tract or an air bar.

In discussing this invention reference has been, and a will be, made toa slot, an air bar, and an air track. A slot is an elongated, linearopening, generally 1 inch or 2 inch wide, in a suspended ceiling definedbetween, for example, the horizontal flanges of spaced inverted T-bars.An air bar is a linear airdiffuser incorporating a means of patterncontrol and including a part of its assembly the basic ceiling supportmembers (e.g. inverted T-bars) forming the slot. An air track is thesame as the air bar but does not include the pattern control, a separatediffuser being used in association with the air track to provide patterncontrol.

Various air plenum constructions, diffuser constructions, andcombinations thereof have been provided in the past. Examples of suchprior constructions can ,be found in various U.S. patents issued toRobert R. Lambert, namely U.S. Pat. Nos. 3,227,063, 3,577,904,3,601,032, 3,601,033, 3,690,243, 3,748,998, and 3,757,667.

This invention is concerned with such constructions and the problemspresented thereby.

SUMMARY OF INVENTION Among the general objects of this invention is toprovide a combination air plenum and airoutlet which achieves airdelivery and return in a suspended ceiling with a minimum ofsubassemblies and on-site installation steps while improving airdelivery charcteristics.

For the achievement of such objects, this invention proposes anelongated, linear air plenum having a passage defining wall which isclosed except for an elongated, linear outlet opening. The length of theoutlet opening is less than the overall length of the air plenum. Anoutlet assembly, e.g. a diffuser or a collar, is attached to the wall atthe outlet opening and is adapted to register with an assembly definingan elongated, linear slot in a suspended ceiling. The air deliveryarrangement so constructed is supported in the ceiling with the plenumbeing spaced from the ceiling support members so that air delivery isprovided through outlet assembly and the slot with a return beingprovided through the portion of the slot adjacent to that portion of theslot receiving air from the outlet assembly.

A number of linear plenum-outlet assemblies can be arranged end-to-endwith open communication therebetween to increase the overall length ofthe air plenum. The increase in length can be such as to extendcompletely across a particular room being serviced or across an entirebuilding floor in which case it may span more than one room. The ceilingslot will also have the same basic extension. Outlet openings areprovided on a plurality of the plenums and are arranged to maintain therelationship necessary to achieve alternate supply and return areas atthe slot.

It will be appreciated that when the plenums are described as beingclosed allowance is still made for connection to a central airsupplythrough a flexible duct.

With this arrangement, a simple assembly is provided which can be usedin a suspended ceiling to provide supply and return areas at a ceilingslot. A minimum of subassemblies have to be handled by the contractordoing the actual assembly and the pattern of supply and return can bereadily varied using the same basic components and without disruptingthe overall ceiling. Where a plurality of end-to-end arrangedplenum-outlet assembly combinations are used and span a number of roomsor areas, the size of the rooms or areas can be varied as desired andthe air supply adjusted to accommodate the change by cutting the plenumand inserting a dam at the appropriate joint or joints.

Other objects and advantages will be pointed out in, or be apparentfrom, the specification and claims, as will obvious modifications of theembodiments shown in the drawings, in which:

FIG. 1 is a perspective view of an air plenum-diffuser assembly;

FIG. 2 is a section view taken generally along lines 22 in FIG. 3;

FIG. 3 is a side elevation of a plurality of the air plenum-diffuserassemblies of FIG. 1 arranged end-to-end in a suspended ceiling;

FIG. 4 is a section view taken generally along lines 4-4 in FIG. 3; and

FIG. 5 is an end view, in section similar to FIG. 2, of an alternativeembodiment.

DESCRIPTION OF PREFERRED EMBODIMENTS With particular reference to thedrawings, an air plenum-diffuser assembly 10 is illustrated as includingan air plenum 12 which is formed of conventional foil covered ductboard. The air plenum has a generally triangular section 14 and aprojecting portion 16. The triangular section forms a linear, elongatedprincipal air passage and projection 16, which extends the length of theprincipal ain passage, forms an extension off of that principal airpassage.

.A sheet metal collar 18 is attached to triangular section 14 andregistered with an air entry opening 20 to provide for connection of theair plenum to a central supply of air. Diffuser assembly 22 is connectedto projection 16 adjacent an elongatedopening 24(see FIG. 2) provided atthe terminal end of projection 16. The construction of the diffuser and.the arrangement thereof relative to the air plenum will be described inmore detail hereinafter.

In FIG. 3 a plurality of the air plenumdiffuser assemblies 12, 12a, and12b are illustrated as they would be assembled end-to-end in a suspendedceiling. More particularly the joints between the adjacent airplemum-diffuser assemblies are connected by means of tape 26 anddiffusers 22 extend between adjacent pairs of cross-runner T-bars 25. Ina conventional manner, cross-runner T-bars 25 extend at right angles tothe main runner T-bars. The main runners are parallel to the two T-bars27 visible in FIG. 2 which are virtually identical to the main runnersbut are closer spaced than normal because they form an air track. Beforedescribing the relationship of the air plenum-diffuser assemblies in thesuspended ceiling, a specific description of a diffuser assembly and itsconnection to the air plenum will be made.

Referring to FIG. 2, diffuser assembly 22 includes side walls 28 and 30spaced apart to provide an air supply passage 32 therebetween. Theopposite ends of the air passage are closed by end plates 34 and 36, seealso FIG. 1. Pattern control means 38 is provided within the air supplypassage 32. The airpattern control includes 3 nesting channel shapedweir members 40 and 42. These weir members are mounted for slidingmovement relative to each other in the air supply passage to providepattern control as well as to control the volume of flow, or completelyclose a passage to flow if desired. The operation and connection of theweir members in the I diffuser are more completely described in RobertR.

Lamberts US. Pat. Nos. 3,411,425, 3,444,801 assigned to the assignee ofthis application, and reliance is placed oh those prior patents for amore complete description of the weir mounting and function should itbecome necessary. For purposes of this invention it should be sufficientto explain that nesting weir members 40 and 42 extend the entire lengthof the linear diffuser 22 and are supported a their opposite endsbetween mounting members 44 and 46. Members 44 and 46 (provided at bothof the opposite ends of the diffuser but only one illustrated in FIG. 3)are connected to the side walls 28 and 30 and hold the weir membersagainst vertical movement while permitting generally unrestricted motionof the weirs between the two diffuser side walls.

The actual connection of the diffuser to the air plenum is made bymachine screws 48 which extend through the upper portions of diffuserwalls 28 and 30, the duct board forming the opposed walls of projection16 of the air plenum and through backing plates 50 and 52 provided onthe interior walls of projection 16. The

. lower ends of walls 28 and 30 rest on the flanges of T- bars 27.Retaining springs 54 and 56 are provided at space points on the walls ofthe diffuser and engage the vertical leg of the T-bars. These springs 54and 56 hold the diffuser rigid between the T-bars minimizing vibrationand also will engae the enlarged upper heads 58 of the T-bars to preventaccidental withdrawal of the air plenum-diffuser from between the twoT-bars.

As mentioned above T-bars 27 are in the nature of main T-bars runners,but are closely associated so as to form the air track describedpreviously. In other words, the horizontal flanges of the T-bars arespaced apart to provide a slot 100 in the ceiling, the regular ceilingtile 60 being supported on the outer flanges of the T-bars.

With this-arrangement, air delivered to the air plenum through openingwill flow through opening 24 in the plenum to passage 32 and willdischarge through slot 100 into the room or other area being serviced.

The suspended ceiling in which the air plenum-dif-- fuser assembly isutilized is of conventional construction and thereforewill not bedescribed in specific detail. It should be sufficient for the purpose ofunderstanding this invention to point out that cross runners 25 are allparallel to each other and extend at right angles to the main runners27, the main runners in turn being all parallel to each other. The crossand main runner T-bas are generally supported by wire hangers and on aspecific dimension module, i.e. defining 2 by 2 feet squares, 4 by 4squares, etc. When one or more air plenum-diffuser assemblies areutilized such as illustrated in FIG. 3, the length of the air plenum,the length of the diffuser attached thereto, and the position of thediffuser on the air plenum are all related to the ceiling module.

As illustrated, the end-to-end arranged air plenums 10 are positionedparallel .to the main runners and the length of the air plenum isselected such that it is greater than the distance between two adjacentcross runners (the plenums could be parallel to the cross runners).Specifically, as illustrated, the length of the air plenum isapproximately twice the distance between adjacent cross runners and thelength'ofdiffuser assembly 22 is approximately equal to the spacingbetween a pair of adjacent cross runners. With this arrangement,diffuser 22 extends between the cross runners 25 virtually completelyfilling that area of the slot 100 which is commensurate with thedistance between those two cross runners while the extensions of the airplenum beyond the diffusers extend over the cross runners toapproximately the midpoint of the adjacent pair of cross runners atwhich point it engages the next adjacent plenum.

In the specific illustrated embodiment the diffusers, being shorter thanthe air plenum, are centered on the plenums and areas 62 and 64 ofprojection 16 on either side of the plenum are closed. Slot 100 extendsthe entire length of the air plenum assembly, or assemblies asillustrated in part of FIG. 3. Thus, there will be a slot extendingacross the cross runners and not only those which have diffusers 22associated therewith. With the air plenum arrangement described, thespaces between, or adjacent the diffusers, can be utilized effectivelyand without undue involvement to provide an air return.

More specifically, the portions of slot 100 which are immediatelyadjacent the slot portions registering with diffusers 22 will bepositioned below the closed areas 62 and 64 of the air plenum and theair plenum is spaced above the cross and main runners as is illustratedin the drawings. This arrangement is partly illustrated in FIG. 4wherein it can be seen that return air can flow upwardly through slot100 into the attic between the suspended ceiling and the actualstructural ceiling. Although no additional elements are necessary toprovide the return air path, a baffleinsert 66 is provided in the airtrack mainly for aesthetic reasons. More specifically, overlappinghorizontal walls 70 and 72 block the line of sight through slot 100 intothe attic so that one in the room being serviced cannot see into theattic through the return air slot.

FIG. 5 illustrates an alternative embodiment wherein the slot 100 isformed in the ceiling by an air bar assembly 91. The air bar assemblyincludes main runners 27 and weirs 40 and 42' supported identical tothat described in connection with the embodiment of FIGS. 1-4 and alsofunctioning in the same manner. With this embodiment, a collar isprovided at opening 24, the collar being provided by longitudinal sidewalls 82 and 84 and end walls 86, only one end wall is illustrated inthe drawing. The collar has shoulders 88 which rest atop the air barT-bars 27 so that the air outlet of plenum l2 registers with the air barfor discharge of air through slot and air is discharged in the samemanner as in the previously described embodiment. The remainder of theair plenum-collar assembly is identical to that described in connectionwith FIGS. 14, returns, etc.

The longitudinal position of the diffuser or collar on the plenums canbe varied as desired. Also, the plenum cross section illustrated is thetype which would be used at a room perimeter or adjacent a lightfixture. It can have other cross-sectional shapes and the outlet neednot be at one side but can be centered or otherwise positioned betweenthe sides of the plenum.

The ends of a single plenum can be closed in a conventional manner, i.e.end plates taped to the plenum body, where one plenum is used or theotherwise open ends of end-to end arranged plenums can be similarlyclosed.

Although this invention has been illustrated and described in connectionwith particular embodiments thereof, it will be apparent to thoseskilled in the art that various changes and modifications may be madetherein without departing from the spirit of the invention or from thescope of the appended claims.

I claim: 1. In combination in a suspended ceiling including a pluralityof ceiling members, a plurality of ceiling support members and meansdefining an elongated slot in said ceiling the improvement of an airdelivery arrangement comprising, in combination,

means including a generally closed tubular wall portion defining anelongated, linear plenum air passage,

means defining an elongated, linear opening in said wall portion andextending parallel to the longitudinal axis of said plenum air passage,

the length of said opening being less than the overall length of saidlinear plenum air passage, means for delivering air to said plenum airpassage for discharge through said opening,

means having a length generally equal to the length of said opening andconnected to said wall portion along said opening for connecting saidopening to said means defining said slot only along a length of saidslot corresponding generally to the length of said opening so that airdelivered to said plenum air passage is discharged through a limitedlength of said slot generally equal to the length of said openmg,

and said linear plenum being spaced from said ceiling support members sothat air is delivered through said slot from said opening while thelength of said slot adjacent that through which air is delivered is inalignment with a closed extension of said tubular wall portion andprovides an air return.

2. The apparatus of claim 1 wherein said means connected to said wallportion at said opening comprises a diffuser assembly including, spacedwalls projecting laterally from said wall portion and defining a passagetherebetween, and pattern control means in said passage to deflect flowthrough said passage prior to discharge through said slot.

3. The apparatus of claim 1 wherein said means connected to said wallportion at said opening comprises a collar having spaced side and endwalls and projecting laterally from said wall portion to define apassage therebetween.

4. The combination of claim 1 wherein said ceiling support memberscomprise a first set of mutually parallel ceiling support members and asecond set of mutually parallel ceiling support members arrangedgenerally perpendicular to said first set,

including a plurality of said linear plenums all generally identical inconstruction and each having a length greater than the spacing betweenadjacent ones of said first set of ceiling support members,

wherein said linear plenums are connected end-toend parallel to saidsecond set of ceiling support members,

and wherein at least two of said linear plenums include said opening andsaid means connected to said wall portions at said opening,

so that air is delivered through portions of said slot from saidopenings while the lengths of said slot adjacent those slot portionsthrough which air is delivered are in alignment with closed extensionsof said linear plenums and provide air returns.

5. The apparatus of claim 4 wherein said means connected to said wallportions at said openings comprise diffuser assemblies including spacedwalls projecting laterally from said wall portions and defining apassage therebetween, and pattern control means in said passages todeflect through said passage prior to discharge through said slot,

and wherein said diffusers are centered relative to the length of saidlinear plenums.

6. The apparatus of claim 4 wherein said means connected to each of saidwall portions at said openings comprises a collar having spaced side andend walls and projecting laterally from said wall portions to define apassage therebetween,

and wherein each of said collars are centered relative to the length ofsaid linear plenums.

7. The apparatus of claim 5 wherein the ceiling support members of saidfirst set are equally spaced,

wherein said linear plenums each have a length substantially twice thespacing between adjacent ceiling support members of said first set,

and wherein said'diffusers have a length substantially equal to thespacing between adjacent ceiling support members of said first set.

8. The apparatus of claim 6 wherein the ceiling support members of saidfirst set are equally spaced,

wherein said linear plenums each have a length substantially twice thespacing between adjacent ceiling support members of said first set,

and wherein said diffusers have a length substantially equal to thespacing between adjacent ceiling support members of said first set.

1. In combination in a suspended ceiling including a plurality ofceiling members, a plurality of ceiling support members and meansdefining an elongated slot in said ceiling the improvement of an airdelivery arrangement comprising, in combination, means including agenerally closed tubular wall portion defining an elongated, linearplenum air passage, means defining an elongated, linear opening in saidwall portion and extending parallel to the longitudinal axis of saidplenum air passage, the length of said opening being less than theoverall length of said linear plenum air passage, means for deliveringair to said plenum air passage for discharge through said opening, meanshaving a length generally equal to the length of said opening andconnected to said wall portion along said opening for connecting saidopening to said means defining said slot only along a length of saidslot corresponding generally to the length of said opening so that airdelivered to said plenum air passage is discharged through a limitedlength of said slot generally equal to the length of said opening, andsaid linear plenum being spaced from said ceiling support members sothat air is delivered through said slot from said opening while thelength of said slot adjacent that through which air is delivered is inalignment with a closed extension of said tubular wall portion andprovides an air return.
 2. The apparatus of claim 1 wherein said meansconnected to said wall portion at said opening comprises a diffuserassembly including, spaced walls projecting laterally from said wallportion and defining a passage therebetween, and pattern control meansin said passage to deflect flow through said passage prior to dischargethrough said slot.
 3. The apparatus of claim 1 wherein said meansconnected to said wall portion at said opening comprises a collar havingspaced side and end walls and projecting laterally from said wallportion to define a passage therebetween.
 4. The combination of claim 1wherein said ceiling support members comprise a first set of mutuallyparallel ceiling support members and a second set of mutually parallelceiling support members arranged generally perpendicular to said firstset, including a plurality of said linear plenums all generallyidentical in construction and each having a length greater than thespacing between adjacent ones of said first set of ceiling supportmembers, wherein said linear plenums are connected end-to-end parallelto said second set of ceiling support members, and wherein at least twoof said linear plenums include said opening and said means connected tosaid wall portions at said opening, so that air is delivered throughportions of said slot from said openings while the lengths of said slotadjacent those slot portions through which air is delivered are inalignment with closed extensions of said linear plenums and provide airreturns.
 5. The apparatus of claim 4 wherein said means connected tosaid wall portions at said openings comprise diffuser assembliesincluding spaced walls projecting laterally from said wall portions anddefining a passage therebetween, and pattern control means in saidpassages to deflect through said passage prior to discharge through saidslot, and wherein said diffusers are centered relative to the length ofsaid linear plenums.
 6. The apparatus of claim 4 wherein said meansconnected to each of said wall portions at said openings comprises acollar having spaced side and end walls and projecting laterally fromsaid wall portions to define a passage therebetween, and wherein each ofsaid collars are centered relative to the length of said linear plenums.7. The apparatus of claim 5 wherein the ceiling support members of saidfirst set are equally spaced, wherein said linear plenuMs each have alength substantially twice the spacing between adjacent ceiling supportmembers of said first set, and wherein said diffusers have a lengthsubstantially equal to the spacing between adjacent ceiling supportmembers of said first set.
 8. The apparatus of claim 6 wherein theceiling support members of said first set are equally spaced, whereinsaid linear plenums each have a length substantially twice the spacingbetween adjacent ceiling support members of said first set, and whereinsaid diffusers have a length substantially equal to the spacing betweenadjacent ceiling support members of said first set.